Body support articles with airflow promoting structure

ABSTRACT

Disclosed herein are body support articles that offer enhanced comfort, hygienic conditions and overall sleep environment. Such body support articles include mattresses and pillows that have at least one layer of material that is copper-infused. Optionally, such body support articles can have a layer of material that serves as an airflow promoting structure. In preferred embodiments, the layer of material that serves as the airflow promoting structure cane be secured to one or more other layers of the article without adhesives or other securement material(s) that can hinder inter-layer breathability.

CROSS-REFERENCE TO RELATED APPLICATIONS

This continuation-in-part patent application claims priority from co-pending U.S. Non-provisional patent application Ser. No. 15/490,580, filed 18 Apr. 2017, entitled “COPPER INFUSED BODY SUPPORT ARTICLES”, having a common applicant herewith and being incorporated herein in its entirety by reference.

FIELD OF THE DISCLOSURE

The disclosures made herein relate generally to body support articles such as mattresses, mattress pads and pillow and, more particularly, to body support articles with an airflow promoting structure.

BACKGROUND

In our sleep-impaired digital era, pursuit of wellness and awareness of sleep hygiene has received unprecedented attention. There have been best-selling books that are dedicated to the topic. Consumer electronic device applications and monitoring devices such as wearables with the capability of tracking users sleep performance have become common-place. As an example of sleep-related health considerations, the Metropolitan Transportation Authority (MTA) in the state of New York has provided sleep apnea screening and, where needed, corresponding treatment for nearly 20,000 transit workers.

The rising awareness of the benefits of sleep has led to an increased focus on the sleeping environment. This increased focus is directed to a host of sleep-affecting factors. These factors include, but are not limited, to comfort of body support articles, environmental considerations such as temperature and humidity, hygienic considerations related to the sleeping environment and body supporting articles, and the like.

The construction of conventional mattresses, mattress pads and pillows are well-known. Such conventional mattresses, mattress pads and pillows often include a woven-fabric cover over a layer of polyester batting and one or more layers of foam or latex rubber supporting the layer of polyester batting. This construction is known to trap body heat and moisture leading to overheating and poor sleep. This hot, humid climate is also well known to promotes the breeding of allergy-causing dust mites and odor-causing bacteria. These adverse hygienic conditions are extremely difficult to eliminate, which is particularly true in the case of a mattress because washing a mattress is not practical. With mattresses being on an average replacement cycle of 7 years, they become progressively more hospitable to unwanted germs and organisms and less hospitable to their intended users.

Therefore, body supporting articles having a construction and being made from materials that overcome drawbacks associated with conventional body supporting articles would be advantageous, desirable and useful.

SUMMARY OF THE DISCLOSURE

Embodiments of the present invention are directed to body support articles that offer enhanced comfort, hygienic conditions and overall sleep environment. More specifically, embodiments of the present invention are directed to mattresses, mattress pads and pillows that have at least one layer of material that is copper-infused and that optionally have a layer of material that serves as an airflow promoting structure. In preferred embodiments, the layer of material that serves as the airflow promoting structure can be secured to one or more other layers of the article without adhesives or other securement material(s) that can hinder inter-layer breathability. Thus, based on the materials and construction of body supporting articles configured in accordance with embodiments of the present invention, such body supporting articles overcome drawbacks associated with conventional body supporting articles.

In one embodiment of the present invention, a body support article upon which a person rests comprises a body supporting structure, an airflow promoting structure, and a cover. The body supporting structure has an upper surface. The airflow promoting structure extends at least partially over the upper surface of the body supporting structure. The airflow promoting structure is in direct contact with the upper surface of the body supporting structure. The cover extending over an entire portion of the airflow promoting structure and at least partially over side and bottom surfaces of the body supporting structure.

In another embodiment of the present invention, a mattress comprises a body supporting structure, an airflow promoting structure, and a cover. The body supporting structure includes at least one layer of foam. The at least one layer of foam defines an upper surface of the body supporting structure. The airflow promoting structure extends at least partially over the upper surface of the body supporting structure thereby defining an airflow promoting structure interface area where the airflow promoting structure overlies the body supporting structure. At least a portion of the airflow promoting structure interface area is devoid of a layer of material that inhibits the airflow promoting structure from being in direct contact with the upper surface of the body supporting structure. The cover extends over an entire portion of the airflow promoting structure and at least partially over side and bottom surfaces of the body supporting structure.

In another embodiment of the present invention, a mattress comprises a body supporting structure, an airflow promoting structure, and a securement structure. The body supporting structure has an upper surface. The airflow promoting structure extends at least partially over the upper surface of the body supporting structure. The securement structure is engaged with the body supporting structure and the airflow promoting structure for limiting unrestricted lateral movement of the airflow promoting structure with respect to the upper surface of the body supporting structure. Such engagement with the body supporting structure includes being engaged with at least one of one or more side surfaces of the body supporting structure and a bottom surface of the body supporting structure.

These and other objects, embodiments, advantages and/or distinctions of the present invention will become readily apparent upon further review of the following specification, associated drawings and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing a mattress configured in accordance with an embodiment of the present invention;

FIG. 2 is a cross-sectional view taken along the line 2-2 in FIG. 1; and

FIG. 3 is an illustrative view showing an airflow promoting structure configured in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

FIGS. 1 and 2 show a mattress 100 configured in accordance with an embodiment of the present invention. The mattress 100 comprises a body supporting structure 102, an airflow promoting structure 104, a moisture transmission layer 106 and a cover 108. The airflow promoting structure 104 extends at least partially over the body supporting structure 102. The moisture transmission layer 106 extends at least partially over the airflow promoting structure 104. The cover 108 extends at least partially over the moisture transmission layer 106. In this manner, as discussed below in greater detail, the body supporting structure 102, the airflow promoting structure 104, the moisture transmission layer 106 and the cover 108 jointly define a resilient structure upon which a body can be supported and that provides for temperature control, moisture extraction and air circulation in conjunction with body supporting functionality thereof.

The body supporting structure 102 can include one layer of material or a plurality of layers of material (i.e., a multi-layer body supporting structure). Each layer of material has a respective upper and lower major surface and perimeter edges between such upper and lower surfaces. In specific embodiments, the body supporting structure 102 can include one or more layers of foam (e.g., polyurethane foam). For example, the body supporting structure 102 can include a first layer of foam (e.g., of a respective stiffness), a second layer of foam (e.g., of a respective stiffness) and optionally one or more additional layers of foam each of a respective stiffness. In this respect, the stiffness of each layer of such a multi-layer body supporting structure can be specified to provide a desired body supporting characteristic at the upper surface of the body supporting structure. It is also disclosed herein that at least one layer of foam can be bisected, whereby side-by-side segments of such bisected layer can be of different stiffness, or a central portion of at least one layer of foam can be of a different stiffness than a perimeter edge portion of the at least one layer of foam.

The airflow promoting structure 104 has respective upper and lower major surface and perimeter edges between such upper and lower surfaces. The lower surface of the airflow promoting structure 104 is engaged with the upper surface of the body supporting structure 102. The airflow promoting structure 104 is configured for allowing air to flow through a mass of the airflow promoting structure 104. The airflow promoting structure 104 can have a construction that allows heat and moisture vapor to readily flow in a generally vertical direction through upper and lower major surfaces of the airflow promoting structure 104 and that allows air to readily flow in a generally horizontal direction through perimeter edges that extend between the upper and lower major surfaces. In a preferred embodiment, the airflow promoting structure 104 can include at least one air passages that extends contiguously from a first one of the perimeter edges to a second one of the perimeter edges (e.g., opposing or adjacent ones of the perimeter edges).

As shown in FIG. 3, in one specific embodiment, the airflow promoting structure 104 can have two opposing fabric layers (i.e., first layer 202 and second layer 204) that are joined by a non-woven material 206 (e.g., microfilament yarn, threads of material, or the like) within an airspace 208 between the two opposing fabric layers 202, 204, thereby creating a breathable three-dimensional laminate. Such a three-dimensional laminate allows for heat and moisture vapor to move vertically through one or both of the opposing fabric layers 202, 204 and for cool air to move into the airspace 208 for ventilating the heat and moisture vapor from the airflow promoting structure 104 through perimeter edges extending between the two opposing fabric layers. In this respect, the airflow promoting structure 104 can provide for temperature control, moisture extraction and air circulation in relation to layers of material engaged with the two opposing fabric layers 202, 204.

Optionally, one of the fabric layers 202,204 can be omitted whereby the airflow promoting structure 104 can have one layer of fabric engaged with the non-woven material 206 provided thereon. The non-woven material can be implemented as one of more layers where each layer is of the same construction or can be two or more or the layers can be of different construction. For example, one layer can be configured to predominately provide for airflow within such layer and another layer can be configured to predominately provide vertical load-carrying capability and/or vertical resiliency (e.g., memory) capability.

Another embodiment of the airflow promoting structure 104 can include a layer of material (e.g., a polymeric material in the form of foam) that has airflow channels and/or passages formed therein. Such channels and/or passages extends from one or more perimeter edges of the airflow promoting structure 104 to a central region thereof. In some embodiments, such channels and/or passages extends between two different edges (e.g., opposing side edges or opposing end edges) of the airflow promoting structure 104.

In still other embodiments, the airflow promoting structure 104 can include a layer of non-woven material (e.g., layer of synthetic or natural batting material) having structural bodies dispersed therein. Such structural bodies provide the functionality of maintaining air spaces within the non-woven material, providing airflow passages within the non-woven material, providing the airflow promoting structure 104 with vertical load-carrying capability, providing the airflow promoting structure 104 with vertical resiliency (memory), and the like.

The moisture transmission layer 106 has respective upper and lower major surface and perimeter edges between such upper and lower surfaces. The lower surface of the moisture transmission layer 106 is engaged with the upper surface of the airflow promoting structure 104. The moisture transmission layer 106, which is optionally omitted in some embodiment of the present invention, serves the primary function of transmitting moisture from the upper surface of the moisture transmission layer 106 moisture transmission layer 106 (e.g., moisture generated by a body supported on the mattress 100) to the lower surface of the moisture transmission layer 106, thereby transferring such moisture to the airflow promoting structure 104. The moisture transmission layer 106 can be made from material that can convey moisture via fibers thereof. Examples of such moisture conveying fibers include, but are not limited to, wool fibers, synthetic fibers treated for providing moisture wicking functionality along a surface thereof, synthetic fibers having a surface thereof configured for providing moisture wicking functionality along the surface thereof, and the like.

The cover 108 extends at least over the upper surface of the moisture transmission layer 106. In preferred embodiments, the cover 108 can be made from have a plurality of pieces of sewn together woven fabric that jointly wrap fully around the top, sides and bottom of the structure jointly formed by the body supporting structure 102, the airflow promoting structure 104 and the moisture transmission layer 106. For example, the cover 108 can have a top piece that extends over the top surface of the moisture transmission layer 106, a bottom piece that extends under the lower surface of the body supporting structure 102 and a side piece that extends over perimeter edges of the structure jointly formed by the body supporting structure 102, the airflow promoting structure 104 and the moisture transmission layer 106.

In conventional implementations, an adhesive would typically be used at an interface of the airflow promoting structure 104 for providing securement to an adjacent layer of material. However, use of adhesive in such a manner is well known to reduce efficiency of the heat transfer, airflow and/or moisture transmission between adjacent material layers of a body support article such as the mattress 100. Accordingly, the airflow promoting structure 104 is preferably engaged with the body supporting structure 102 and the moisture transmission layer 106 in a manner that limits its unrestricted movement therebetween but that does not adversely impact heat transfer, airflow and/or moisture transmission between the airflow promoting structure 104 and either the body supporting structure 102 or the moisture transmission layer 106. For example, the airflow promoting structure 104 can extend at least partially over the upper surface of the body supporting structure 102 to define an airflow promoting structure interface area where the airflow promoting structure 104 overlies the body supporting structure 102 and all or a portion of the airflow promoting structure interface area is devoid of a layer of material (e.g., adhesive) that inhibits the airflow promoting structure 104 from being in direct contact with the upper surface of the body supporting structure 102. Such inhibition of direct contact can adversely impact heat transfer, airflow and/or moisture transmission between the airflow promoting structure 104 and the body supporting structure 102. To this end, in one embodiment, as shown in FIG. 2, the airflow promoting structure 104 includes a retention element 112 that extends from a perimeter edge portion 114 of the airflow promoting structure 104 into engagement with a side surface 116 of the body supporting structure 102. The retention element 112 can be secured to the side surface 116 of the body supporting structure 102 by means such as, for example, adhesive, hook and loop fastener, mechanical fastener, stitching, cinch band, elastic band or the like. Alternately or additionally, the retention element 112 can be secured to a lower surface 118 of the body supporting structure 102 or can be secured over the body supporting structure 102 via a skirt with cinch band, a skirt with elastic band, cinch or elastic straps or the like. Regardless of the specific means of securement of the airflow promoting structure 104 to the body supporting structure 102, such securement is preferably implemented in a manner that does not adversely impact heat transfer, airflow and/or moisture transmission between the airflow promoting structure 104 and the body supporting structure 102.

It is disclosed herein that the cover 108 can be configured to be removable, thereby allowing access to the body supporting structure 102, the airflow promoting structure 104, and the moisture transmission layer 106. It is also disclosed herein that the airflow promoting structure 104 and the moisture transmission layer 106 can each be selectively removable (e.g., attached in a manner providing for selective detachment and attachment) for allowing replacement and/or cleaning (e.g., laundering) thereof. Alternatively, the moisture transmission layer 106 can be integral with the cover 108 and the airflow promoting structure 104 can be selectively removable.

Advantageously, one or more components of the mattress 100 (e.g., the body supporting structure 102, the airflow promoting structure 104, the moisture transmission layer 106 and/or the cover 108) can be made from a copper-infused material. Copper has known anti-fungal and antibacterial properties as well as relatively high thermal conductivity. Accordingly, implementation of such one or more components of the mattress 100 with a copper infused material imparts anti-fungal and antibacterial properties that beneficially impact anti-odor, temperature regulation and hygiene performance of the mattress 100.

In some embodiments of the present invention, the cover 108 is preferably made from a material that is infused with particles of copper. For example, the cover 108 can be made from a woven fabric comprising a plurality of threads that have copper particles associated (e.g., embedded or otherwise imparted) therewith. The copper particles can be integral with the threads themselves such as, for example, being integrated into the threads during or after manufacture of the threads or can be provided onto the threads of the fabric after such threads are formed into the woven fabric. A copper-infused thread that can be weaved or knitted in combination with other fibers into a fabric suitable for use as a cover of a body supporting article that is configured in accordance with embodiments of the present invention is commercially available from Next Fiber Technology, LLC under the tradename CuTEC®.

In some embodiments of the present invention, the body supporting structure 102 (e.g., one or more layers thereof) is preferably made from a material that is infused with particles of copper. For example, the body supporting structure 102 can include a layer of foam material that is infused with copper particles. In the case of the body supporting structure 102 including a plurality of layers of foam, one or more layer of foam (e.g., only the uppermost layer or all but the lowermost layer) can be made from a material that is infused with particles of copper. Such copper-infused material can include copper particles being deposited on an exterior surface of the layer of foam, copper particles being deposited on the layer of foam within open cells thereof (i.e., an open-cell foam), copper-containing gel deposited on a surface of the foam-material, or a combination thereof. A copper-containing additive for use as an additive in manufacturing copper-infused open cell foam is commercially available from Peterson Chemical Technology, Inc. under the tradename CopperGel™. A copper-infused open cell foam suitable configured for use as a layer of a body supporting article that is configured in accordance with embodiments of the present invention is commercially available from Peterson Chemical Technology, Inc. under the tradename CopperGel™ Visco.

In view of the disclosures made herein, a person of ordinary skill in the art will understand that a mattress is a first type of body supporting article that can be configured in accordance with embodiments of the present invention. Such person of ordinary skill in the art will also understand that embodiments of the present invention can include other types of body supporting article. A pillow, which can include a cover, a moisture transmission layer, an airflow promoting structure, and a body supporting structure, is a second type of body supporting article that can be configured in accordance with embodiments of the present invention. A mattress pad, which can include a cover, a moisture transmission layer and an airflow promoting structure, is a third type of body supporting article that can be configured in accordance with embodiments of the present invention. The constituent components of such types of body supporting article (e.g., cover, moisture transmission layer, airflow promoting structure and body supporting structure) can be configured in the manner disclosed above in reference to the mattress 100, thereby similarly providing for beneficial anti-odor, temperature regulation and hygiene performance.

Although the invention has been described with reference to several exemplary embodiments, it is understood that the words that have been used are words of description and illustration, rather than words of limitation. Changes may be made within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the invention in all its aspects. Although the invention has been described with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed. Rather, the invention extends to all functionally equivalent technologies, structures, methods and uses such as are within the scope of the appended claims. 

1. A body support article upon which a person rests, comprising: a body supporting structure having an upper surface; an airflow promoting structure extending at least partially over the upper surface of the body supporting structure, wherein the airflow promoting structure is in direct contact with the upper surface of the body supporting structure, wherein the airflow promoting structure extending at least partially over the upper surface of the body supporting structure defines an airflow promoting structure interface area where the airflow promoting structure overlies the body supporting structure, wherein an entire portion of the airflow promoting structure interface area is devoid of a layer of material that inhibits the airflow promoting structure from being in direct contact with the upper surface of the body supporting structure, wherein the airflow promoting structure includes at least one retention element that extends at least partially over side surfaces of the body supporting structure, wherein the at least one retention element is engaged with said side surfaces of the body supporting structure and wherein the airflow promoting structure is secured to the body supporting structure exclusively by said engagement of the at least one retention element with said side surfaces of the body supporting structure; and a cover extending over an entire portion of the airflow promoting structure and at least partially over side and bottom surfaces of the body supporting structure.
 2. The body support article of claim 1 wherein the at least one retention element includes a skirt engaged with said side surfaces of the body supporting structure for securing the airflow promoting structure to the body supporting structure.
 3. The body support article of claim 1 wherein: the airflow promoting structure includes upper and lower major surfaces jointly defining a plurality of perimeter edges extending between the upper and lower major surfaces; and at least one air passage extends contiguously from a first one of the perimeter edges to a second one of the perimeter edges.
 4. (canceled)
 5. (canceled)
 6. The body support article of claim 1 wherein the airflow promoting structure includes spaced-apart woven fabric layers and a layer of non-woven material therebetween.
 7. (canceled)
 8. The body support article of claim 6 wherein the airflow promoting structure includes at least one retention element that extends at least partially over side surfaces of the body supporting structure for securing the airflow promoting structure to the body supporting structure.
 9. (canceled)
 10. A mattress, comprising: a body supporting structure including at least one layer of foam, wherein the at least one layer of foam defines an upper surface of the body supporting structure; an airflow promoting structure extending at least partially over the upper surface of the body supporting structure thereby defining an airflow promoting structure interface area where the airflow promoting structure overlies the body supporting structure, wherein an entire portion of the airflow promoting structure interface area is devoid of a layer of material that inhibits the airflow promoting structure from being in direct contact with the upper surface of the body supporting structure, wherein the airflow promoting structure includes a skirt that extends at least partially over side surfaces of the body supporting structure, wherein the skirt is engaged with said side surfaces of the body supporting structure and wherein the airflow promoting structure is secured to the body supporting structure exclusively by said engagement of the skirt with said side surfaces of the body supporting structure; and a cover extending over an entire portion of the airflow promoting structure and at least partially over side and bottom surfaces of the body supporting structure.
 11. (canceled)
 12. The mattress of claim 10 wherein: the airflow promoting structure includes upper and lower major surfaces jointly defining a plurality of perimeter edges extending between the upper and lower major surfaces; and at least one air passage extends contiguously from a first one of the perimeter edges to a second one of the perimeter edges.
 13. (canceled)
 14. The mattress of claim 10 wherein the airflow promoting structure includes spaced-apart woven fabric layers and a layer of non-woven material therebetween.
 15. (canceled)
 16. (canceled)
 17. A mattress, comprising: a body supporting structure having an upper surface; an airflow promoting structure extending at least partially over the upper surface of the body supporting structure; and a securement structure engaged with the body supporting structure and the airflow promoting structure for limiting unrestricted lateral movement of the airflow promoting structure with respect to the upper surface of the body supporting structure, wherein said engagement with the body supporting structure includes being engaged with at least one of one or more side surfaces of the body supporting structure and a bottom surface of the body supporting structure, and wherein the airflow promoting structure is secured to the body supporting structure exclusively by said securement structure.
 18. The mattress of claim 17 wherein: the airflow promoting structure includes upper and lower major surfaces jointly defining a plurality of perimeter edges extending between the upper and lower major surfaces; and at least one air passage extends contiguously from a first one of the perimeter edges to a second one of the perimeter edges.
 19. The mattress of claim 17 wherein: the airflow promoting structure extending at least partially over the upper surface of the body supporting structure defines an airflow promoting structure interface area where the airflow promoting structure overlies the body supporting structure; and an entire portion of the airflow promoting structure interface area is devoid of a layer of material that inhibits the airflow promoting structure from being in direct contact with the upper surface of the body supporting structure
 20. The mattress of claim 19 wherein the airflow promoting structure includes spaced-apart woven fabric layers and a layer of non-woven material therebetween. 